AS9102 Rev C first article inspection for aerospace and defense CNC parts. Forms 1, 2, and 3 produced in-house in Hanover, PA.
AS9102 Rev C First Article Inspection at Olympus Machining. Form 1 part number accountability, Form 2 product accountability for raw material and processes, Form 3 characteristic accountability for every drawing dimension. Performed in-house with Haas HMM 430 and Chien Wei CWB-450-CNC CMMs.
About AS9102 First Article Inspection (FAI)
AS9102 First Article Inspection (FAI) at Olympus Machining LLC is delivered from our ITAR-registered precision CNC machine shop in Hanover, Pennsylvania (York County). This page (https://www.olympusmachining.com/as9102-first-article-inspection) documents the scope, controls, and engineering practices we apply for OEM, aerospace, defense, and medical buyers requesting as9102 first article inspection (fai).
Olympus Machining is CAGE 9V9P0, CMMC Level 1 self-attested per FAR 52.204-21, and NAICS 332710. CMM dimensional inspection is performed in-house on Haas HMM 430 and Chien Wei CWB-450-CNC. AS9102 Rev C First Article Inspection packages, material certifications with heat/lot traceability, and Certificates of Conformance are produced on request as part of as9102 first article inspection (fai).
To request a quote, supplier qualification documentation, or a controlled copy of our capability statement related to as9102 first article inspection (fai), contact info@olympusmachining.com or call (717) 634-5094. Olympus Machining LLC, 639 Frederick Street Suite 1, Hanover, PA 17331.
AS9102 First Article Inspection (FAI) Guide for CNC Machined Parts
AS9102 is the SAE International aerospace standard governing First Article Inspection (FAI) for parts and assemblies delivered to aerospace and defense customers. Olympus Machining LLC — an ITAR-registered, CAGE 9V9P0 precision CNC machine shop in Hanover, Pennsylvania (York County) — produces AS9102 Rev C documentation packages for every qualifying first article we ship.
This guide explains what AS9102 requires, walks through Form 1, Form 2, and Form 3, and details the FAI workflow we use on our coordinate measuring machines — the Haas HMM 430 and the Chien Wei CWB-450-CNC. Internal links connect to our precision CNC machining, CNC milling, and CNC turning capability pages.
What AS9102 Is and When It Is Required
AS9102 (currently Revision C, released August 2023) defines the minimum requirements for documenting that a first production article complies with the engineering drawing, purchase order, and applicable specifications. It applies to parts and assemblies for aerospace, defense, and space programs governed by AS9100 quality management systems. Most prime contractors flow AS9102 down to subtier suppliers contractually — meaning that if a prime requests a first article on your part, an AS9102-conformant FAI package is the deliverable.
FAI is required when (1) a part is produced for the first time, (2) the design, tooling, process, or supplier changes, (3) a lapse of two or more years has occurred since the last production run, or (4) the customer specifies it on the purchase order. Common triggers include a revision change to the drawing, a material substitution, a change in the manufacturing facility, or a change in the inspection method.
Rev B vs Rev C key differences: Revision C clarifies the treatment of digital product definitions (model-based definition, or MBD), expands guidance on partial FAIs (PFAI), and tightens the rules around traceability of special processes. Rev C also formalizes the treatment of additive manufacturing characteristics. Olympus Machining produces FAI packages to the customer-specified revision — most current programs require Rev C.
Form 1 — Part Number Accountability
Form 1 establishes the identity of the part being inspected. It captures the part number, part name, drawing number and revision, serial or lot number, manufacturing process record (router, traveler, or work order number), and whether the FAI is a full FAI or partial FAI (PFAI). For assemblies, Form 1 also lists every sub-component part number and indicates whether each sub-component has its own FAI.
Olympus Machining populates Form 1 from the customer purchase order and our internal job traveler. Because we operate under documented procedures with traveler-controlled revision tracking, the Form 1 entries are pulled directly from the work order rather than transcribed by hand — eliminating the most common source of Form 1 rejections (mismatch between part revision on the form and the revision actually built).
Form 2 — Product Accountability for Materials and Special Processes
Form 2 documents the raw material certifications and any special processes (heat treat, plating, anodizing, passivation, NDT, welding) applied to the part. Each line item captures the specification (e.g., AMS-QQ-A-250/11 for 6061-T6 plate, or AMS 2700 for stainless passivation), the actual certification number, the name of the supplier or processor, and the date of certification.
Olympus Machining maintains material certifications and process certifications in a controlled job folder for every order. For special processes routed to outside vendors — anodizing, plating, heat treat, NDT — we require Nadcap-accredited (where applicable) or customer-approved suppliers, and the certification copies are bound into the FAI package alongside our internally generated documentation.
For ITAR-controlled parts, Form 2 also documents the chain of custody from raw material receipt through finished part — supporting the traceability requirements of FAR 52.204-21 and our CMMC Level 1 alignment.
Form 3 — Characteristic Accountability
Form 3 is the dimensional report. Every drawing characteristic — dimension, tolerance, GD&T callout, surface finish, material requirement, and note — is assigned a balloon number on a balloon-annotated drawing. Form 3 then lists, for each balloon: the requirement (nominal and tolerance), the actual measured value, the inspection method (CMM, micrometer, gage pin, vision system), and the accept/reject result.
Olympus Machining produces balloon drawings using High QA and equivalent inspection planning software. The balloon drawing becomes the master reference for Form 3 entries, ensuring that no characteristic is missed and that balloon numbering is consistent between the drawing and the form.
Every callout on the customer print is assigned a unique balloon number using High QA. The balloon drawing is reviewed against the engineering drawing for completeness before any chips are cut.
2. Build the CMM program
Inspection programs are written for the Haas HMM 430 (3-axis CMM) and the Chien Wei CWB-450-CNC (CNC CMM with rotary table) to capture every dimensional characteristic on the balloon drawing.
3. Machine the first article
The part is machined on our 3-, 4-, or 5-axis CNC mills or live-tooling lathes using the documented setup that will be used for production. The first piece off the setup is the first article.
4. Run CMM and supplemental inspection
The CMM program is executed; non-CMM characteristics (threads, surface finish, visual notes) are inspected with appropriate hand tools, gages, and visual references.
5. Populate Form 1, Form 2, Form 3
Form 1 is pulled from the traveler; Form 2 from the controlled certification folder; Form 3 from the CMM output and supplemental inspection records.
6. Internal review and customer delivery
The FAI package is reviewed by our quality lead before being released. The customer receives a PDF package — and, for ITAR programs, the package is delivered through controlled channels per the customer's program security requirements.
Common FAI Rejection Reasons (and How We Prevent Them)
Form 1 part revision mismatch
Form 1 fields are auto-populated from the work order traveler — no manual transcription.
Missing material certification on Form 2
Material cert is uploaded to the controlled job folder at the time of receiving inspection. The FAI package will not release without it.
Balloon numbers on Form 3 don't match the drawing
Balloon drawing is the single source of truth for balloon numbering — Form 3 is generated from it.
Drawing review is performed before ballooning. Notes and datum callouts are explicitly balloon-numbered, not assumed.
Inspection method not stated or not appropriate
Inspection method is selected per characteristic during CMM programming and recorded in the inspection plan.
Out-of-tolerance condition shipped without disposition
Any out-of-tolerance characteristic triggers an internal MRB review. The part is not shipped until disposition (rework, use-as-is with customer concurrence, or scrap) is documented.
AS9102 Form Templates
Blank AS9102 Rev C Form 1, Form 2, and Form 3 templates are published by SAE International. Customers and engineering teams should download the official templates directly from SAE to ensure they are using the current revision:
Olympus Machining produces FAI packages on the official SAE Rev C forms (or the customer-specified revision when different). Customers do not need to supply blank templates — we provide the completed package.
Printable Pre-Submission FAI Checklist
Engineering and procurement teams can use this checklist before submitting a part for first-article. Each item maps to a section of the AS9102 Rev C package Olympus delivers; missing inputs are the single largest cause of FAI re-work.
Released drawing PDF at the revision being machined (no markups, no 'preliminary' watermarks).
3D model (STEP or IGES) matching the drawing revision — required for MBD characteristics.
Material specification on the drawing or PO (e.g., AMS 4928 Ti-6Al-4V bar, 6061-T6 plate AMS-QQ-A-250/11).
Outside-process specifications called out where applicable (heat treat, anodize Type II/III, passivation per AMS 2700, NDT method).
Key Characteristics (KCs) clearly flagged on the drawing, with measurement method and frequency identified.
PO clearly states FAI required (full or partial), revision of AS9102 (Rev C default), and any deviation from standard form.
If PFAI: prior FAI report number provided, plus the list of characteristics affected by the change.
Source-inspection or government-source-inspection requirements identified at quote stage, not post-machining.
Acceptable surface finish callouts for areas not explicitly noted (default per ASME Y14.36 or customer spec).
Marking requirements specified (laser, ink stamp, vibro-peen) with location and content.
Packaging and preservation callouts specified (corrosion protection, individual bagging, MIL-STD-2073 if applicable).
Browser print preview ("Ctrl/Cmd + P") produces a one-page hand-off checklist for engineering review meetings.
AS9102 First Article Inspection FAQ
Request FAI on Your Next Order
Submit your drawing along with a note that you require an AS9102 first article inspection. We will quote the FAI as a separate line item with a clear scope.